I came across this due to I was searching for a transmission issue and saw this. But I had the EXACT same issue just this past September. The blower worked, on all vent settings, but when the temperature setting was adjusted, to any heat level, with exception of it being at the coldest temp setting, I had nothing but cold air blowing out with the continous clicking noise. There was no heat from any of the vent settings. I took it to a Ford dealer to diagnose and repair, and it was in fact the Blend Door; just as already suggested by bobneu. It was a little pricey though, just less than $1000.00 for the dealer to repair, due to the fact it is located under the dash that had to be dismantled to get to it. Most of the cost to repair was labor, not the part, that was less than $50.00. If you do know someone who won't mind spending the time to dismantle the dash and putting it back, then I definately would go that route. It will cost alot less than taking it to a dealer.
To troubleshoot this types of problem,click the link below
:----http://howtobyme.blogspot.in/2012/02/heater-blows-only-from-defrost.html
--------Go through the procedure to confirm the
issue.
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Engine Overheats and heater
blowing cold?
http://howtobyme.blogspot.com/2011/11/engine-overheats-and-heater-blowing.html
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Heat blows cold on drivers
side and hot on passenger side?
http://schematicsdiagram.blogspot.com/2011/12/heat-blows-cold-on-drivers-side-and-hot.html
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No heat on car?
http://technoanswers.blogspot.in/2012/02/no-heat-on-oldsmobile-silhouette.html
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Heater blows intermittently and temp
gauge goes erratic?
http://technoanswers.blogspot.com/2012/01/heater-blows-intermittently-and-temp.html------------Heater blows cold?
http://schematicsdiagram.blogspot.in/2012/02/heater-blows-cold.html
---------Car heater blowing warm, but not
hot air?
http://schematicsdiagram.blogspot.com/2011/12/car-heater-blowing-warm-but-not-hot-air.html--------
Heater/AC blower motor not working?
http://technoanswers.blogspot.in/2012/02/heaterac-blower-motor-not-working-on.html
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A/C, heater, defroster fan, not
working?
http://technoanswers.blogspot.in/2012/02/ac-heater-defroster-fan-not-working.html
Heater problem?
http://technoanswers.blogspot.in/2012/02/heater-problem-on-isuzu-trooper.html---------
This will help.Thanks.
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I have the exact same problem as above(doily_131).
2002 ford explorer, had clicking sound under dash it blows air but it is cold air. tell me what this is.
reviewing your problem I need to know the following
1 is it electronic? ( the temp is shown on a display)
2. is it a standard temp control with red and blue temp selector fan control and directions ( upper vents ,floor defrost etc.)
Does the blower work on defrost? If you are hearing air but not getting warm air the problem most likely is in the blend door located under the dash board on passenger side. If you have mechanical ability get a Chilton book for the vehicle and follow the step by step directions. It can be intimidating but with common sense and some patients you can repair this your self
WHEN YOU TURN THE TEMP DIAL TO HOT IT STARTS TO MAKE A KLICKING NOISE. ALMOST LIKE A FLAP IS STUCK ON FROZEN
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